Systems and methods for servicing ball valves

ABSTRACT

A temporary ball valve support structure is utilized to apply pressure on the ball in a ball valve so that a seal is maintained between the ball portion of the valve and one seal member. This prevents fluid from leaking from the valve while the valve is being serviced by ensuring that there is a good seal between the ball valve and the seal closest to the fluid filled tank or pipe. The temporary ball valve support allows a outermost ball valve seal and the ball valve retainer housing assembly to be removed. This allows the outer seal and retainer to be replaced and/or serviced without allowing fluid to be escape from the tank. First and second clamping members are alternately used to force the ball member against the seal closest to the fluid container.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention is generally directed to the field ofservicing and repairing ball valves. More specifically, the presentinvention includes systems and methods for servicing ball valves in avariety of locations including railroad tank cars.

[0003] 2. Description of the Related Art

[0004] While others have proposed solutions to the problem of repairingand servicing ball valves, the existing proposed solutions to thisproblem are inadequate. Ball valves are used in a wide variety of fluidsystems. They are typically utilized in fluid filled tanks or pipes asvalves for releasing fluid when desired. They are typically highlyreliable and employ few moving parts. However, the life of a ball valveis not limitless. The seals employed by a ball valve will wear out overtime.

[0005] A typical ball valve assembly is comprised of a circular or ringseal member that is placed adjacent to one orifice in the valve. Theball portion of the ball valve is located adjacent to this seal member.The ball portion is comprised of a spherical member that has a hollowcentral core typically in the shape of a cylinder that extends from oneside to the other. The ball valve also typically includes a further ringseal located adjacent to the ball so that the ball valve housing pressesagainst it thereby providing a tight compression fit between the seals,the ball member and the orifice. The ball member may be mechanicallyrotated so that in a first position no fluid is allowed to flow becausethe ball member forms a seal with the upper and lower (or upstream ordownstream) seal ring. When the ball member is rotated, the hollow coreis then aligned with the orifice, thereby allowing fluid to flow.

[0006] Conventional methods for servicing and replacing ball valvestypically require that the fluid container or pipe to which the ballvalve is secured be completely drained so that fluid will not flow fromthe tank or pipe when the ball valve is being serviced. While in manyinstances this is not a problem, there are certain circumstances whereit is difficult or otherwise undesirable to remove all of the fluid froma tank or pipe on which a ball valve is located. For example, in therailroad industry, when ball valves on railroad tank cars requireservice, the conventional solution is to completely remove all the fluidfrom the tank car so that the ball valve attached to the car may beserviced. This is difficult and often highly undesirable, particularlyif the car that requires service is out in the field away from theservice depot or cleaning facility.

[0007] One characteristic of ball valves is that the downstream sealtypically fails prior to the upstream seal member of the ball valve.This is due to the fact that when a ball valve is used for drainingfluid from a tank, the ball valve is usually located in a lowermostregion of the tank. This is for the obvious reason that fluid needs toflow from the tank when it is being drained. For example, most railroadtank cars typically include a ball valve located in the lowermost pointof the tank car. Due to this location, the fluid in the tank typicallyapplies a significant downward force on top of the ball valve therebyapplying greater pressure to the lower seal member of the ball valve.This increases the wear on the lower seal member of the ball valve. As aresult, ball valves require servicing at various intervals. However,another characteristic of ball valves, due to the design characteristicsrecognized above, is that the lower seal member will need to be servicedmore often than the upper seal.

[0008] Currently there is no known system for easily and convenientlyservicing ball valves on railroad tank cars or, and other locationswhich can be safely used on cars, tanks and pipes that have not beencleaned. U.S. Pat. No. 5,975,104 discloses a ball valve seal replacementapparatus and method. However, the systems and methods described in thispatent require the use of a jig and a jack-screw which is cumbersome andmay be difficult to use. Accordingly, there remains a need in the fieldfor improved systems and methods for servicing ball valves.

[0009] The present inventor has overcome the shortcomings of the priorart and identified new systems and methods for replacing and servicingball valves on railroad tank cars as well as other locations. Otherobjects and advantages of the present invention will be apparent fromthe following summary and detailed description.

SUMMARY OF THE INVENTION

[0010] The present invention is directed to improved systems and methodsfor servicing and replacing ball valves on railroad tank cars as well asball valves in other locations and structures. In accordance with thepresent invention, a temporary ball valve support structure is utilizedto apply pressure on the lower portion of the ball in the ball valve sothat a seal is maintained between the ball portion of the ball valve andthe seal member closest to the tank, pipe or other adjacent structure.This prevents fluid from leaking from the valve while the valve is beingserviced by ensuring that there is a good seal between the ball portionof the ball valve and the seal closest to the fluid filled tank.

[0011] In accordance with the present invention, a temporary ball valvesupport is provided which allows the downstream ball valve seal and theball valve housing assembly to be removed. This allows the lower sealand to be replaced and/or serviced without requiring fluid to be removedfrom the tank. In one embodiment, the temporary support may be securedto the lower portion of a fluid tank, or to the lower portion of thevalve or simply supported by the ground beneath a railroad tank car orother fluid tank or to another structure.

[0012] All that is necessary is that the temporary support provide asecure foundation for applying a force against the ball member of theball valve. In the preferred embodiment of the present invention, thesystem and method employs first and second lever support members. Thesetwo members are utilized in order to ensure that force may be applied tothe ball member at all times when the ball valve is being serviced.

[0013] In utilizing the systems and methods of the present invention,the ball valve temporary support is initially secured beneath the ballvalve. The temporary support structure may be secured directly to anadjacent tank or pipe connected to the ball valve or any other adjacentstructure including the floor or ground beneath the ball valve.

[0014] After the temporary support structure has been secured, firstball support member is inserted within the ball valve temporary support.This first ball support member applies a force on a portion of the ballmember thereby ensuring that the seal is maintained between the ballmember of the ball valve and the seal member closest to an adjacent tankor pipe. Once this occurs, and while force is being applied from thefirst ball support member, the lower ball valve seal and any othernecessary portions of the ball valve assembly may be detached from thevalve.

[0015] The portions of lower ball valve assembly and the lower seal aredropped down around the first lever support member. The first ballsupport member maintains a force on the ball valve to maintain a sealbetween the ball member and the first seal. Once the lower ball valveassembly portions and the lower or second seal member have been loweredaround first ball support member, a second ball support member issecured within the temporary support structure.

[0016] The second lever member then applies a force against the ballmember of the ball valve thereby securing the ball member against thefirst seal. The first ball support member is then removed, therebyallowing lower seal and ball valve assembly portions to be freelyremoved. The lower seal member may be serviced and/or replaced. This isaccomplished simply by securing a new seal around the first leversupport member, if the seal is being replaced along with any othernecessary parts from the ball valve assembly.

[0017] The first ball support member is then utilized to apply a forceagainst the ball member while a force is also applied by the second ballsupport member. The second ball support member may then been removedwhile a force is still applied by the first ball support member. This isnecessary so that the lower seal assembly may be secured whilepreventing the ball valve from leaking. The first ball support membermay then been removed after the lower seal member and all of the ballvalve assembly components are secured in place. Finally the temporarysupport structure is also removed.

[0018] This can all be accomplished without requiring that fluid beremoved from the tank. Those skilled in the art will appreciate thatalthough the invention has been described with respect to a verticalball valve arrangement, it will work equally well with any other ballvalve arrangement, as all that is required is that the system andmethods utilized in accordance with the present invention apply a forceon the ball member of the ball valve to ensure that a seal is maintainedbetween the ball member of the ball valve and the seal closest to thetank or line.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019]FIG. 1 illustrates a typical ball valve assembly;

[0020]FIG. 2 illustrates a temporary support structure and a first ballsupport member;

[0021]FIG. 3 illustrates a step for removing a lower portion of a ballvalve assembly;

[0022]FIG. 4 illustrates a step for removing a lower portion of a ballvalve assembly;

[0023]FIG. 5 illustrates a step for removing a lower portion of a ballvalve assembly;

[0024]FIG. 6 illustrates a step for removing a lower portion of a ballvalve assembly;

[0025]FIG. 7 illustrates a step for removing a lower portion of a ballvalve assembly;

[0026]FIG. 8 illustrates a step for replacing a lower portion of a ballvalve assembly;

[0027]FIG. 9 illustrates a step for replacing a lower portion of a ballvalve assembly;

[0028]FIG. 10 illustrates a final step for replacing a lower portion ofa ball valve assembly;

[0029]FIG. 11 illustrates an adjust able bolt for altering the placementof the lever support;

[0030]FIG. 12 illustrates a plan view of an adjustable bolt for alteringthe placement of the lever support;

[0031]FIG. 13 illustrates a locking mechanism for securing one of thelever support members in place while the ball valve is being serviced;and,

[0032]FIG. 14 illustrates a detailed view of a locking mechanism forsecuring one of the lever support members in place while the ball valveis being serviced.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

[0033]FIG. 1 illustrates a typical ball valve assembly shown generallyat 10. The ball valve assembly is in fluid communication with a channel12 that is typically connected to a fluid container tube or pipe. Thisposition is desired so that fluid may flow from the container or tank.The ball valve assembly is comprised of an upstream seal 14 and a ballmember 16. The upstream seal 14 and downstream seal 15 are circular andprovide a fluid seal between the ball member 16 and an orifice whichopens into channel 12. The ball member 16 is typically formed of a metalsphere with a centrally located hollow core. The ball member 16 may berotated from a first position where the hollow core is aligned with theorifice to allow fluid to flow from the container. In a second position,a side wall of the ball member 16 presses against the upstream seal 14and downstream seal 15 thereby preventing fluid from flowing out of thetank.

[0034] The ball valve assembly is further comprised of a valve body 20and a retainer plate 22. The retainer plate applies a force on thedownstream seal member in the direction of the ball member and the firstseal member and secures the overall assembly to the valve. The retainerplate 22 also has a central orifice 24 which allows fluid to flow fromthe tank when the ball valve is aligned such that the hollow coreprovides a path for fluid communication with the channel 12.

[0035] As shown in FIG. 2, a temporary ball valve support structure 26is utilized to apply pressure on the lower portion of the ball member 16in the ball valve so that a seal is maintained between a portion of theball member 16 and the upstream seal member 14. This prevents fluid fromleaking from the valve while the valve is being serviced by ensuringthat there is a good seal between the ball valve and the seal closest tothe fluid filled tank or pipe.

[0036] The temporary ball valve support structure 26 allows thedownstream seal 15 and retainer plate 22 and other associated parties tobe replaced and/or serviced without requiring fluid to be removed fromthe tank or pipe to which the ball valve is connected. In oneembodiment, the temporary support may be a secured to the lower portionof a fluid tank as shown. In an alternate embodiment, the temporarysupport structure may be supported by the valve, by the ground beneath arailroad tank car or similarly beneath any other fluid tank or pipe.Alternatively, yet another structure may provide this support. Thoseskilled in the art will appreciate that a wide variety of structures maybe utilized for providing the temporary support and force against theball member 16 of the ball valve. Clamping force may be generated bylevers, jacks, wedges or other mechanical devices. This embodiment usesweighted levers to apply clamping force to the ball.

[0037] In the embodiment illustrated in FIG. 2, the temporary supportstructure is comprised of elongated struts or support members 27 and 28that are connected to the tank or pipe. Although not shown, theelongated support members 27 and 28 are each actually comprised of twodistinct members or a single structure with a space or slot in between.This gap or space allows first and second lever members to pass through.FIG. 2 illustrates a first lever 31 which passes through a slot or spacein the elongated support structure 28. The first lever 31 pivots on thecorresponding first pivot member 33. The second pivot member 34 is alsoshown in FIG. 2.

[0038] All that is necessary is that the temporary support provide asecure foundation for applying a clamping force against the ball memberof the ball valve. In utilizing the systems and methods of the presentinvention, the ball valve temporary support is initially secured beneathor adjacent to the ball valve. A first lever member 31 is insertedwithin the ball valve temporary support. This step is illustrated inFIG. 2. FIG. 3 illustrates lever 31 pivoting on pivot member 33. Asshown in FIG. 3, a separate force applying member 36 may be utilized toensure uniform application of force on ball member 16. Specifically thisforce applying member 36 desirably has a curvature which matches thecurvature of ball member 16. This first lever member 31 applies a forceon the lower portion of the ball valve thereby ensuring that the seal ismaintained between the ball member 16 of the ball valve and the upstreammember 14.

[0039] As shown in FIG. 4, once this occurs, and while force is beingapplied on the ball member 16 by the first lever member 31, thedownstream ball valve seal 22 and other portions of the ball valveassembly 24 may be removed.

[0040] The portions of downstream ball valve retainer plate 22 and theseal member 15 are dropped down around the first lever support member31. The first lever support member 31 maintains a force on the ballmember 16 of the ball valve to maintain a seal between the ball member16 and the upstream seal 14. Once the desired ball valve retainer plateand the downstream seal member have been lowered around first leversupport member 31, a second lever support member 38 is secured withinthe temporary support structure 27. This is illustrated in FIG. 5. Thesecond lever support member 38 is located opposite the first leversupport member 31. The second lever support member 38 pivots on pivotmember 34. The second lever support member 38 is located in a slot orgap within support 27.

[0041] The second lever support member 38 then applies a force againstthe ball member 16 of the ball valve thereby securing the ball member 16against the upstream seal 14. The first lever support member 31 is thenremoved, thereby allowing downstream seal 15 and ball valve retainerplate portions 22 to be freely removed. This step is illustrated in FIG.6. The downstream seal member 15 and or retainer plate 22 or otherexposed parts may then be serviced and/or replaced. FIG. 7 illustratesthe second lever support member 38 exclusively providing force to ballmember 16.

[0042]FIG. 8 illustrates a step wherein the downstream seal member 15has been replaced with the necessary retainer plate 22 beneath thedownstream seal member 15 all of which are placed around the first leversupport member 31 which has not been replaced within its respectivelocation in the temporary support structure. The first lever supportmember 31 is then utilized to apply a force against the ball member 16while a force is also applied by the second lever support member 38. Thesecond lever support member 38 may then be removed while a force isstill applied by the first lever support member 31. This is necessary sothat the downstream seal 15 and corresponding retainer plate 22 may besecured to the valve while preventing the ball valve from leaking. Thesesteps are shown in FIGS. 9 and 10.

[0043] The first lever support member 31 may then been removed after thefirst seal member and all of the ball valve assembly components aresecured in place. Finally the temporary support structure 26 is alsoremoved. This can all be accomplished without requiring that fluid beremoved from the tank. Those skilled in the art will appreciate thatalthough the invention has been described with respect to a verticalball valve arrangement, it will work equally well with any other ballvalve arrangement, as all that is required is that the system andmethods utilized in accordance with the present invention apply a forceon the ball member of the ball valve to ensure that a seal is maintainedbetween the ball member of the ball valve and the seal closest to thetank or line.

[0044] In the preferred exemplary embodiment of the present invention,the frame of the temporary ball valve support structure is secured inplace via bolts, one of which is illustrated in FIGS. 11 and 12. Asshown in FIGS. 11 and 12, one or more of the bolts which secure the baseof the temporary ball that support structure in place is located withinan orifice which allows for alternate placement of the bolts withrespect to the base of the temporary ball valve support structure asshown. This aspect of the design of the preferred embodiment is providedin order to assure that lever support may be securely located directlybeneath the ball valve to be serviced. Specifically, the location forthe base of the temporary ball valve support structure may be adjustedsimply by loosening the bolts which secure the base of the leversupport, placing the lever support in its desired location andthereafter securing the bolts in place.

[0045]FIG. 13 illustrates a further alternate preferred embodiment ofthe present invention wherein a locking mechanism is provided in orderto secure one or more of the lever support members 28, 31 in place. FIG.13 illustrates placement of the locking mechanism 52 on lever supportmember 31. Although only one locking mechanism is shown, those skilledin the art will recognize that one or more of the locking mechanism 52may be utilized in order to secure the lever support members in place.One is sufficient to secure the ball valve in place during servicing andthereby eliminating the potential for inadvertently dropping the ballvalve and spilling any fluid contained in the container or pipe.Specifically, as shown in FIG. 13, lever support member 31 has a hole 54for receiving locking member 52. In the preferred exemplary embodiment,locking member 52 is simply designed as a u-bolt, however those skilledin the art will recognize that alternate mechanical lacking mechanismsmay be utilized as well as alternate placements for the locking themechanism. For example, a notch may be formed in the lever supportmember 31 and the u-bolt may be secured over the notch. Other structuresmay be utilized as well for mechanically securing the lever support 31in place.

[0046]FIG. 14 illustrates the details of the locking member 52. As shownin FIG. 14, locking member 52 fits through a hole 54 in lever support31. Wing nuts 56 and 58 secure plate 55 in place over the base of thesupport structure. As shown in FIG. 13, a catch 60 prevents lockingmember 52 from slipping out of place. Catch 60 is preferably a simplepin member that is secured in a hole as shown. This pin member extendsat least from one side to engage the U-bolt 52. In the preferredembodiment, pin 60 is an L-shaped member. In FIG. 14, pin 60 is shown inits inserted state.

[0047] It should be recognized that various modifications to thestructures and methods disclosed herein may be made while neverthelessfalling within the scope of the appended claims. For example, it iscontemplated that the lever support members may apply force to astructure other than directly to the ball member of the ball valve. Thisother structure may then transmit the force to ensure the seal betweenthe ball member and the first seal member. The embodiments disclosedherein are exemplary only and those skilled the art will appreciate thatthose structures may be modified but nevertheless incorporate thepresent invention.

I claim:
 1. A method of servicing a ball valve comprising the steps of:applying a force to a ball member of a ball valve with a first forceapplying member; removing a first seal member from a location adjacentthe ball member; applying a force to the ball member with first andsecond force applying members; and applying a force to the ball memberexclusively with the second force applying member and removing a seal ofthe ball valve.
 2. A method of servicing a ball valve of claim 1,further comprising an additional step of: prior to the step of applyinga force to the ball member with the first force applying member,securing a temporary support structure adjacent the ball valve.
 3. Themethod of servicing a ball valve of claim 2, further comprising anadditional step of securing the first force applying member on thetemporary support structure.
 4. The method of servicing a ball valve ofclaim 3, further comprising an additional step of securing the secondforce applying member on the temporary support structure.
 5. A temporarysupport structure for a ball member of a ball valve comprising: a basefirst and second lever support member slots or guides extending fromsaid base; pivot members opposite said first and second lever supportmember slots or guides; and first and second lever support memberssecured within the respective first and second lever support memberslots or guides.
 6. The temporary support of claim 5, furthercomprising: first and second base supports extending from said first andsecond lever support member slots to secure the base to a tank.